Method of making laminated shingles

Abstract

A method for manufacturing laminated shingles achieves heretofore unobtained versatility by employing separate rolls of substrate materials for underlayment and overlayment webs of the laminated shingles being made. The method contemplates that each of the underlayment and overlayment webs are separately coated with an asphalt composition and granule formulation, whereby the asphalt compositions and/or granule formulations and patterns can be different for each of the webs. Each of the webs is subdivided into plural web portions, which are thereafter laminated, and transversely cut for formation of individual laminated shingles. Laminated shingles formed in accordance with the present method may comprise underlayment and overlayment substrates which differ in thickness, with differing asphalt compositions applied thereto, and/or different granule color formulations and patterns applied to the underlayment and overlayment.

What is claimed is:  
     
       1. A method of making laminated shingles, comprising the steps of: 
       providing a first roll of substrate material to provide an underlayment web to form an underlayment for each of said laminated shingles;  
       providing a second roll of substrate material to provide an overlayment web to form an overlayment for each of said laminated shingles;  
       subdividing said underlayment web along the length thereof into plural subdivided underlayment web portions;  
       subdividing said overlayment web along the length thereof into plural subdivided overlayment web portions;  
       laminating respective ones of said underlayment web portions and said overlayment web portions to form plural laminated webs; and  
       transversely cutting each of said laminated webs into individual laminated shingles.  
     
     
       2. A method of making laminated shingles in accordance with  claim 1 , including: 
       providing the material of said first roll in a thickness and/or composition that differs from the thickness and/or composition of the material of the second roll.  
     
     
       3. A method of making laminated shingles in accordance with  claim 1 , including: 
       applying an asphalt coating to each of said underlayment and overlayment webs prior to said subdividing steps, and  
       subsequently applying a granule formation onto the asphalt coating on each of said underlayment and overlayment webs.  
     
     
       4. A method of making a laminated shingle in accordance with  claim 3 , wherein: 
       said asphalt applying step includes applying an amount of asphalt coating on said underlayment web that differs from the amount of asphalt coating applied to said overlayment web.  
     
     
       5. A method of making a laminated shingle in accordance with  claim 3 , wherein: 
       said asphalt applying step includes applying an asphalt composition onto said underlayment web which differs from an asphalt composition applied onto said overlayment web.  
     
     
       6. A method of making a laminated shingle in accordance with  claim 3 , wherein: 
       said granule formation applying step includes applying a granule formation on said underlayment web that differs from a granule formation applied to said overlayment web.  
     
     
       7. A method of making a laminated shingle in accordance with  claim 1 , wherein: 
       said step of subdividing said overlayment web includes cutting said overlayment web to form each of said plural subdivided overlayment webs with a non-linear profile.